Engine loading and testing system



Nov. 20, 1945. M. P. WINTHER ENGINE LOADING AND TESTING SYSTEM Filed Aug. 11, 1943 3 Sheqts-Sheet 1 1945- M. P. WINTHER ENGINE LOADING AND TESTING SYSTEM Filed Aug. 11, 1943 3 Sheets-Sheet 2 Nov. 20, 1945. M. P.WINTHER ENGINE LOADING AND TESTING SYSTEM Filed Aug. 11, 1943 3 Sheets-Sheet 3 Ill/ll Patented Nov. 20, 1945 UNITED STATES PATENT OFFICE 7 2,339.57: moms comma AND rns'rnvo srs'rm Martin P. Winther, Waukegnn, lll., admito Martin P. Wintlier, as trustee Application August 11, 194:. Serial No. 49:,155

5 Claims. (01. 11-134) This invention relates to an engine loading and testing system and with regard to certain more specific features, to electrical power recovery means for such a system.

Among the several objects of the invention may be noted the provision of an improvement upon known synchronous-generator powen-recovery systems for engine test purposes, in which improvement a dynamometer form of slip coupling is used which will enable loading and testing of an engine for power output and other purposes from practically any low speed up to and beyond the synchronous speed of the generator; the provision of a device of the class described with which the engine may be electrically driven and tested for certain p poses; and ,the provision of apparatus of this class which is very flexible in application, whereby various engine test factors may be easily determined, either with full accuracy, or such approximate accuracy as may be deemed sufficient. Other objects will be in part obvious and in part pointed out hereinafter.

The invention accordingly comprises the elements and combinations of elements, features of construction, and arrangements of parts which will be exemplified in the structures hereinafter described, and the scope of the application of which will be indicated in the following claims.

In the accompanying drawings, in which are ilustrated several of various possible embodiments of the invention, 7

Fig. l'is a vertical section of an electrical slip coupling type of dynamometer; and,

Figs. 2, 3 and 4 are diagrammatic sectional layouts of various forms of the invention, the views being taken primarilyfrom above.

Similar reference characters indicate corresponding parts throughout the several views of the drawings.

In the American Institute of Electrical Engineers, Technical Paper No. 43-41, December, 1942, is discussed the arrangement of a power-recovery test system for aircraft engines. This consists primarily of a synchronous generator driven through a hydraulic slip coupling by the engine under test. The intention is to convert engine output into electrical energy, which energy is then supplied to the power mains of the engine testing plant. The slip coupling is to provide for power-recovery engine operation over a wide range of above synchronism, while driving the synchronous machine which operates only at its one synchronous speed. The slip coupling described in said publication is of the hydraulic typeandactsasamerexrandnotas 55 a dynamometer. There is no locking of the driven shaft of the coupling for such purposes as will hereinafter be described.

The present invention functions not only as a transmission between the engine under test and the generator, but also as a selectively operable dynamometer which is available for obtaining torque measurements for brake horsepower test purposes both below and above synchronous speed. The invention also permits the use of the synchronous generator as a motor for driving the test engine for purposes of loosening up a green engine, making lubrication studies, and the like. It also permits of engine loading below or above synchronous speeds without testing for torque.

Referring now more particularly to Fig. 1,

' there is shown a slip coupling type of power-absorption dynamometer which is to be used, and this will first be described.

At numerals I and I are shown pedestals for the unit which is as a whole indexed D. This dynamometer D consists of a case 5 which, in several forms of the invention, swings in the pedestals I and I on bearings I. As will be noted from Fig. 1 the case '5 includes hubs 22 from which hollow trunnions 4 extend outward through the bearings 1, Thus the case 5 along with its hubs .22 and trunnions 4, may swing in the pedestals I and I. This swinging movement is limited, as will appear, by application of moment to a weighing scale 6i (Fig. 2')

7 At numeral 9 is the power input shaft to which the engine E to be tested is coupled. At its flanged end II this shaft is coupled to one enclosing head I: of an eddy-current inductor drum IS. The other enclosing head I! of the inductor drum is carried on a pilot bearing IS. The hearing it is located around the driven shaft 2!, as is also a pilot bearing 23, which forms a support for the head It. The bearing 25 allows free rotation of the input shaft 9 within the swinging case 5; and a bearing 21 allows free rotation of the output shaft 2! in the case 5. Inward extensions 6 from the hubs 22 form grooved or capillary water seals with cylindric portions 88 of the heads I! and", the purpose of which is to provide protection against entry of water into any of the bearings. As will later appear, water circulates between the case 5 and the drum It. On the inner ends of the cylindric portions II are internally grooved or capillary seals it around shaft 1|. These seals are within bearings I! and 23 respectively. They prevent escape oi lubricant.

The outer race structures II o! the bearings I are made rotary in the pedestals I and 3 respectively, being formed with gear teeth It with which are meshed pinions 24. The latter are carried on shafts II passing through the pedestals I and 3 respectively, At their other ends these shafts II carry square heads II for application from time to time of a wrench to cause angular displacement of the outer races II. The purpose of this is from time to time to bring new parts of the bearings I into position so as to prevent spalling or any given part or the bearing.

Since the case I rocks only through a small angle.

bearings I (unlike ordinary ball bearings) do not rotate through 360. Hence in the absence of an adjustment the lower parts of these bearings I would continuously support the weight, and as a result the continuous vibration of the machine would cause these lower parts to deteriorate by spalling. Devices of this nature are known as hand-operated, rotatable trunnion bearing sleeves and are commonly used in the dynamometer industry. In some constructions the outer races are continuously slowly rotated by a motor drive.

The driven shaft 2|, within the drum II and heads I! and II, has keyed thereto 9. held spider 2! which carries exciter coils II, suitably energized from an outside source by collector rings scribed) for applying torque force to the dynamometer measuring scale II, also to be described.

In Fig. 2 is shown one embodiment of the apparatus of Fig. 1 in a new power-recovery system. At E is shown the engine to be tested. in this case an airplane engine which rotates the drive shaft 9 and inductor drum II. By means above described the drum II, with slip, drives spider 20 and the driven shaft 2|. The drum II and spider 2s rotate within the swinging or rocking housing I within which the water spray is maintained.

The shaft II is coupled to the rotor II of a synchronous generator indicated generalb' at G. The new member II o! the synchronous generator is-carried in a housing 41, which, in the 2| within the housing II.

' From the above, it is clear that in Fig. 2, both "the cases I and I are trunnion mounted. as disand lead-in wiring, the wiring passing through so suitable channels (not shown) in the shaft H. The details of the lead-in means are not shown,

since the manner in which this is managed is drum II. This water flows down to a sump I3 from which it is removed by suitable flexible tubing. For applicable water abstracting means, see my U. S. patent application for Dynamometer, Serial No. 491,101, filed June 17, 1943, eventuated as Patent 2,367,636, dated January 16, 1945. similar water cooling features for a similar inductor drum are shown in my United States patent application, Serial No. 439,205, filed April 16, 1942, for Eddy-current coupling, eventuated as Patent 2,334,976, dated November 23, i943. In this latter patent, however, no swinging case is shown. Suitable free-running water seals are used between the heads I; and II respectively and the case I. also as described in the last-mentioned application. These seals 35 are of the centrifugal type which prevent most if not all leakage. The additional seals 66 prevent any small amount of water which may escape through seals II from entering any of the bearings i, I9, 23, II or 21. The water is introduced onto the member II from a manifold 31 having a supply pipe II and inlet spray openings II for projecting a spray or water onto the drum II.

From the above, it will be seen that there may be relative rotary motion between the drum II (driven by the shaft 9) and the spider 2s (coupled to the driven shaft II). It is also clear that the casing I swings freely through a limited angle in the pedestals I, and I and around both of the relatively rotary members I5 and 2!. Thus the swinging casing I forms a. plenum chamber ior the water cooling spray and also the rocking means (under conditions to be detinguished from foot mounting in which no rocking is possible.

The rocking generator field housing 41 is provided with an arm II, the end of which bears upon a scale I! for evaluating torque force on the field housing.

The case I of the dynamometer D is also provided with a torque arm II bearing upon a scale II for evaluating torque force on the casing.

Between the dynamometer unit D and the senerator G, the driven shalt 2! is provided with a clutch C having a splined element II. A second element II is carried on and with an extension II from the rocking case I. A clutch-operating lever is shown at II, and it will be understood that this may be manually, hydraulically. pneuatically or electrically operated, as desired. It will be understood that any of various types of clutches may be used at this point, the general principle being that a locked coupling is to be obtained between the driven shaft 2i and the case I, which coupling may be opened or closed either when the shaft 2! is rotating or when it is stationary. The clutch C when closed stalls the generator G.

Various operations of the Fig. 2 form of the then loaded at the desired speed and the held member II is energized. so as to eflect an electromagnetic slip between drums I! and II. This generates heat in the drum II which is carried 01! by the water between the outside of the drum II and the case I. The result is that torque due to energy conversion is transmitted from the engine E and drum II to the spider II and the coupled case I. Since the latter is trunnion mounted, the arm It applies a force to the scale II. In addition, any torque due to hydraulic action of the water on case I which spins of! from the outside of the drum II regi ters additional force on the scale II. Hence, the speed of drum II being known. by means of one readningonthescaleIhlllthedataonforeeisob- This idly rotates the inductor drum II.

tained for making a complete and accurate calculation of the engine power as absorbed in both electrical and water losses. Under these conditions scale I1 is not used. It will be apparent that, if the dynamometer D is designed large enough, dynamometer readings can be taken throughout the whole power range of the engine at any speed above or below the synchronous speed of G, since G is. under the stated clutch locked conditions, not operating at all.

Under the above conditions and assuming a 68-inch (plus) arm II, the calculation for obtaining engine horsepower is obtained by multiplying the R. P. M. of shaft I by the scale read-- ing in pounds on scale ll, all divided by 1000. This calculation includes all of the horsepower absorbed in electrical slip and water loss.

If the dynamometer D is designed smaller, so as to absorb all energy at engine speeds only below the synchronous speed of the generator, then horsepower ratings above synchronous generator speed are obtained as follows:

The held 3! of member 20 is first deenergized, and the clutch C is opened, as indicated in Fig. 2. Thus no energy ilows from the engine E through'the dynamometer D nor is it transmitted to shaft II. The synchronous generator G may be started at full voltage being connected to the line in the conventional synchronous motorizing manner, assuming that it has the necessary amortisseur windings for the purpose. As is known, a synchronous machine such as G may function as a motor or generator, depending upon whether mechanical energy is being abstracted from it or delivered to it. The generator G having attained synchronous speed, the engine E may, by energizing il, be cranked for starting and/or running-in purposes at lower than synchronous speed. Finally, the engine may be fired, and brought up to a speed the same as, or above this synchronous speed. Then assuming the field Ii of member 2! to be energized and the clutch C open, we have a slip coupling between members is and 20 and, since the clutch C is open, the rotor 43 of the generator may be operated at its synchronous speed, which causes the generator .G to supply current to the lines connected therewith. It the engine E is rotating above the synchronousispeed of G, the stated slip occurs between i5 and 29 and varies as the engine speed changes. Since the stator 45 of the generator G is cradled in a rocking mount, as described, its arm 5 presses upon the scale ll and from readings thus attained in addition to scale readings at I, engine horsepower calculations can be made for engine speeds above synchronism. I 5

' With the form of the invention shown in Fig. 2 assuming the clutch C to be open and the shaft 2| to be operating at synchronous speed (engine R. P. M. of shaft I, multiplied by the reading in pounds on scale OI, all divided by 1000.

To obtain total horsepower the results 0! the above three terms (a). (b) and (c) are added to give the total horsepower being delivered by the en ine E.

Itwill be understood that, when, as above first described, the dynamometer D is made large enough to obtain all torque readings necessary over the whole range oi engine speeds, both below and above the synchronous speed of generator G (operation with clutch-C locked), the generator G has no function during horsepower measuring tests. It functions to absorb power from the engine under other circumstances. one of which has been described (clutch C open).

A further use is as follows (Pig. 2).

With the clutch C open and the case I held against rotation, the generator G may, as above indicated, be operated as a synchronous motor. When the held I! is energized, the motcrizing generator then drives the engin E through the slip coupling existing between drums II and II. This is a useful procedure fo making friction or lubrication tests, for turning over a "green" engine, or for other purposes. The reactions registered on the scales I! and II and the various relative speeds are again used for horsepower computations, as above made clear in connection with open clutch operation.

If the dynamometer D is made large enough to absorb all energy at all speeds of the engine E, both above and below synchronous speed, as above described, and if it be not desired to measure energy for turning the engine E from the generator G, then it is not necessary to mount the case ll of the generator in a rocking mount, that is, the bearings 48 may be eliminated along with the arms II and scale ll.

40 foot mounting the generator case 41, as indicated E operating above synchronous speed), the factors to be summed up for obtaining engine horsepower are as follows, assuming 63 inches (plus) for the eilective radii of arms I! and 59:

(a) Horsepower due to electrical slip loss between the rotors i5 and 2! equals the difference between the R. P. M. of shafts Q and II multiplied by the readings in pounds on scale 51, all divided by 1000.

(b) The. horsepower, delivered by alternator G equals the R. P. M. of shaft 2] multiplied by the scale readings in pounds on scale 51, all divided by 1000.

(c) The horsepower due to water loss between.

therotorliandthecaselisequaltothe at 8 in Fig. 3. Any horsepower tests with the engine E driving are then made with the clutch C closed. as shown in Fig. 3, thus causing all torque force data to a.ppear on scale II, as in the case with Fig. 2 when the clutch C was assumed to be shut. It is of course to be understoodthat in Fig. 3 clutch C may be opened when torque tests through the cm I are not necessary. This allows for driving the generator which will produce current for power recovery. Such driving may be desired in running in an engine. In Fig. 3, as in Fig. 2, the clutch C when closed stalls the enerator G. V

In Fig. 4 the generator G is foot mounted as at I and the dynamometer coupling D is cradled but neither the clutch C nor scale Ii is used. Instead, a removable arm is is. temporarily clamped to a huh I on the shaft II and allowed to act upon a scale II. In place of the scale ii, an arm 13 is caused to reach from the casing 5' to the arm 68. This impresses moment from the casing I to said am II, in addition to the moment which arm 69 receives from the slip coupling between I! and 20. The clutch C is not used, or, it in place, it is released. In this Fig. 4 case, the engine horsepower is equal to the R. P. M. of shaft I multiplied by the reading in poimds on scale H, all divided by 1000. assuming 83-inch (plus) eflective radius for arm I. This calculation takes into account the electrical slip loss and the water loss, the water loss being taken care of by transmission of torque through the extension ll. When power recovery is desired, thearmtlisremovedandthecase Iisblocked against swinging. for example by allowing arm This involves 4 asses-m "It to engage a stationary object. Under these conditions torque measurements are notpossible; but substantial power recovery may be had by the generator action. Such driving again may bedesiredinrunninginanengine.

The electrical slip coupling herein described has per se advantages over hydraulic couplings which will not develop suflicient torque. below synchronous speeds or an alternator to act properly as dynamometers or with a locked output shaft. Furthermore, hydraulic couplings are not reversible in direction, so that clockwise or counterclockwise rotation oi engines can be accommodated on one machine.

The present construction also eliminates the complex water-regulating systems that are required to maintain pressure for hydraulic cou- D w if used as dynamometers.

In designing the apparatus the following should 5 one oi such shafts carrying a iield member and the other an inductor member electro-magnetically cooperating with the iield member. said inductor member surrounding said field member, a casing surrounding said inductor member, a

mount for cradling said casing with respect to said shafts, means for circulating a cooling medium between said casing and the inductor member for absorbing heat irom the latter, openable clutch means between the driven shaft and said cradled case. and scale means responsive to movement of the case to register lull torque I force when the clutch is closed.

3. A combined dynamometer and slip coupling comprising a driving shalt. a driven shatt, one

be noted in setting the synchronous speed at so 01 such shafts W111!!! I field member and the which the generator operates. When synchronous speeds are-selected that are very low, that is, those that lie in the range of very low engine power, then the alternator cannot produce a large enough proportion of its true capacity at synchronous speed and the system becomes too ineiiicient. It is thus better to select a higher synchronous speed. Since there is a need for testing engines at speeds lower than the. above mentioned desired and relatively high synchronous speed.rthe schemes herein outlined for obtaining capacity below this synchronous speed are very useful. That is to say, the invention provides a means which will enable testing or the engine below synchronous speed oi. the alternator, besides above this speed. It also allows for stalling of the synchronous generator so that engines can be loaded at any speeds including those above and below the synchronous speed oi the generator.

In view of the above, it will be seen that the several objects of the invention are achieved and other advantageous results attained.

As many changes could be made in the above constructions without departing from the scope of the invention, it is intended that all matter contained in the above description or shown in the'aceompanying drawings shall be interpreted as illustrative and not in a limiting sense.

I claim:

1. A combined dynamometer and slip coupling comprising a driving shaft. a driven shaft, one of said shafts carrying a hold member and the other an inductor member electric-magnetically sponsive to torque applied thereto from the driven shaft by said clutch when closed.

4. A combined dynamometer and slip coupling comprising a driving shalt, a driven shaft, one of such shaits carrying a field member and the other an inductor member electro-magnetically cooperating with the field member to absorb energy, said inductor member comprising a liquid-sealed drum surrounding said field member, a liquid-sealed casing surrounding said inductor member and movable relatively thereto,

a cooling liquid being located between the drum and the casing, a connection between the driven shalt and the casing, a weighing scale, and means for applying force to said scale due to moment from said casing and moment from said driven is member, the total moment being that due to 1'0- tary action of the liquid between said casing and said inductor member and also due to electrical torque between the inductor and field members at least some of said moment being delivered air through said connection to the casing.

5. Engine test apparatus comprising a synchronous generator, a slip coupling capable of absorbing power having a driving element and a relatively rotary driven element, said driving cooperating with the field member said inductor element being coupled to the engine and said member surrounding said field member, a casing surrounding said inductor member and movable relatively thereto. means for circulating a cooling medium through said-casing. and around the inductor member and means for registering torque due to slip between the inductor and field members comprising an operable clutch connecting the field member and the casing and measuringgneans associated withsaid casing ior deterdriven element being coupled to the synchronous generator, a casing surrounding said driving and driven elements of the slip coupling and containing fluid, a mount for said casing whereby it may rock, a measuring scale and means coupling said casing and the scale to register force on the scale due to torque irom the casing.

MARTIN P. WINTHER, 

